MacDon R216 User manual

R216
Rotary Disc Header
Operator’s Manual
215026 Revision A
Original Instruction
The harvesting specialists.

R216 Rotary Disc Header
1030661
Published October 2019.
© 2019 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.
Noise Levels
The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M1240), when
operated in conjunction with this R216 Rotary Disc Header, is 70 dBA. This measurement was taken in accordance with ISO
5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well as the exact type of self-
propelled vehicle used to power the R216 Rotary Disc Header.

Introduction
This instructional manual contains safety, operating, and maintenance procedures for the MacDon R216 Rotary Disc
Header. The rotary disc header when attached to a MacDon M1240 Windrower, is designed to cut, condition, and lay a
wide variety of grasses and hay crops in windrows.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Use this manual as your first source of information about the machine. If you follow the instructions provided in this
manual, and use MacDon parts, the rotary disc header will work well for many years. If you require more detailed service
information, contact your Dealer.
Use the Table of Contents and the Index to guide you to specific topics. Study the Table of Contents to familiarize yourself
with how the material is organized. Keep this manual handy for frequent reference and to pass on to new Operators or
Owners. Call your Dealer if you need assistance, information, or additional copies of this manual.
When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant
MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous
situation.
MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy
of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your
Dealer. Damage resulting from any of the following conditions will void the warranty:
•Accident
•Misuse
•Abuse
•Improper maintenance or neglect
•Abnormal or extraordinary use of the machine
•Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the rotary disc header faces the crop.
•Unless otherwise noted, use the standard torque values provided in this manual.
1028900
A
Manual Storage Case
Store the operator’s manual and the parts catalog in the plastic
manual case (A) on the left fixed deflector.
NOTE: Keep your MacDon publications up-to-date. The most
current version can be downloaded from our website
www.macdon.com or from our Dealer-only site
(https://portal.macdon.com) (login required).
215026 iRevision A

Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Section Summary of Change Internal Use Only
Inside front cover Added copyright statement. Tech Pubs
Introduction, page i Added note about dealer portal access. Tech Pubs
Summary of Changes, page ii Added list of changes page. Tech Pubs
1.8 Locating Safety Decals, page 9 Changed in safety decals and location. UECN 31081
1.9 Understanding Safety Signs, page 11 Changed in safety decals and location. UECN 31081
2.1 Specifications, page 13 Added feeding elements section. Engineering
2.1 Specifications, page 13 Disc speed changed to 2650 rpm. Engineering
2.1 Specifications, page 13 Added poly roll option. ECN 58790
3.2.1 Engaging and Disengaging Header
Safety Props –M1240 Windrower, page 20
Revised step. Tech Pubs
3.3.1 Installing Forming Shield, page 22 Added topic. Service Dept
3.3.2 Attaching Header to M1240
Windrower, page 24
Revised topic. Service Dept
3.3.3 Connecting R216 SP Hydraulics and
Electrical to an M1240 Windrower, page 29
Replaced the following topics:
•Connecting Disc Header Hydraulics Using
Hard Plumbing –M1240 Windrowers
•Connecting Disc Header Hydraulics Using
Quick Couplers –M1240 Windrowers
Tech Pubs
3.3.3 Connecting R216 SP Hydraulics and
Electrical to an M1240 Windrower, page 29
Revised note. Engineering
3.4.1 Detaching R216 Rotary Disc Header
from M1240 Windrower, page 36
Revised topic.
3.4.2 Removing Forming Shield, page 40 Added topic. Service Dept
Adjusting Skid Shoe Height, page 48 Added topic. Service Dept
Adjusting Gauge Roller Height, page 49 Added topic. Service Dept
3.7.4 Ground Speed, page 53 Revised call out on illustration. Service Dept.
3.8 Conditioner, page 54 Added polyurethane roll information. ECN 58790
3.8.1 Roll Gap, page 54 Added polyurethane roll information ECN 58790
Adjusting Roll Tension, page 56 Added polyurethane roll information. ECN 58790
Adjusting Roll Gap –Polyurethane Rolls,
page 55
Added topic. Tech Pubs
Adjusting Roll Timing, page 57 Revised illustrations to correct driveline
phasing.
ECN 58852
Adjusting Roll Timing, page 57 Revised Steps 11 to 13. Service Dept.
215026 ii Revision A

Section Summary of Change Internal Use Only
Positioning Forming Shield Side Deflectors –
Roll Conditioner, page 61
Removed Step 2. Engineering
3.9 Cutterbar Deflectors, page 65 Added topic. Tech Pubs
3.9.1 Removing Cutterbar Deflectors, page
65
Added topic. Tech Pubs
3.9.2 Installing Cutterbar Deflectors, page 66 Added topic. Tech Pubs
4.4.1 Maintenance Schedule/Record, page
76
Deleted footnote and revised change icon to
lubricate icon in the last entry.
Engineering
4.4.2 Break-In Inspections, page 78 Removed the 25 hours converging drum and
roller belt inspection interval.
Service Dept
4.4.2 Break-In Inspections, page 78 Added 25 and 100 hours drive belt inspection
interval.
Engineering
4.5.2 Lubrication Locations, page 81 Changed in feedroll belt from two belts to
three belts.
ECN 58581
Draining the Cutterbar, page 86 Revised steps. Engineering
Filling Cutterbar with Lubricant, page 87 Added a step on disengaging the windrower lift
cylinder.
Service Dept.
4.6.2 Cutterbar Discs, page 88 Added image. Engineering
Removing Cutterbar Discs, page 90 Added links to removing the outboard cutterbar
discs.
Engineering
Installing Cutterbar Discs, page 92 Added links to installing the outboard cutterbar
discs.
Engineering
Installing Cutterbar Discs, page 92 Removed Step 1 (Installing spacer plate). Tech Pubs
Installing Cutterbar Spindles, page 96 Added illustration and note on using disc
timing tool.
Service Dept
4.6.4 Disc Blades, page 101 Removed information about 11° bevel-down
blades—not for R2 Series.
Service Dept.
Installing Disc Blades, page 107 Added step to remove pin. Service Dept.
Installing Suspended Drums, page 119 Removed step about installing driveline shield. Service Dept.
Replacing Left Suspended Drum Drive Belt,
page 120
Added topic. Service Dept
Replacing Right Suspended Drum Drive Belt,
page 124
Added topic. Service Dept
Removing Left Driven Drum and Driveline,
page 126
New drum shields. ECN 58758
Installing Left Driven Drum and Driveline,
page 129
New drum shields. ECN 58758
Removing Right Driven Drum and Driveline,
page 132
New drum shields. ECN 58758
Installing Right Driven Drum and Driveline,
page 135
New drum shields. ECN 58758
Removing Cutterbar Spindle Shear Pin, page
139
Replaced image to show a sheared shear pin
and added step.
Service Dept
215026 iii Revision A

Section Summary of Change Internal Use Only
Installing Cutterbar Spindle Shear Pin, page
143
Revised procedure. Service Dept
Changing R216 SP Cutterbar Crop Stream
Configuration, page 147
•Revised note re disc timing tool—it is
included with the header.
•Added location of tool on the header.
Service Dept
4.9.2 Removing Cutterbar Curtain, page 156 Revised illustration. Tech Pubs
4.9.2 Removing Cutterbar Curtain, page 156 Revised Step 1. Service Dept.
4.9.3 Installing Cutterbar Curtain, page 157 Added step. Service Dept.
4.10.1 Inspecting Conditioner, page 158 Changed illustrations to show three
feedroll belts.
ECN 58581
4.12.3 Replacing Header Disc Speed Sensor,
page 169
Revised Step 6. Service Dept.
5.1 Cutterbar Deflectors –MD #B6847, page
171
Added topic. Tech Pubs
5.2 Double Windrow Attachment –MD
#C2070, page 172
Added topic. Tech Pubs
5.3 Disc Feed Plate Kit –MD #B6669, page
173
Added topic. Tech Pubs
5.5 Adjustable Gauge Roller Kit –
MD #B6855, page 175
Added information. Service Dept
5.6 Polyurethane Intermeshing Roller –MD
#B6661, page 176
Added topic. ECN 58790
5.7 Steel Intermeshing Roller –MD #B6662,
page 177
Added topic. Tech Pubs
5.8 Adjustable Skid Shoes Kit –MD #B6848,
page 178
Added information. Service Dept
5.8 Adjustable Skid Shoes Kit –MD #B6848,
page 178
Replaced MD #B6667 with MD #B6848. ECN 58703
6.2 Mechanical Problems, page 184 Removed the symptom: Header slows when
going uphill
Engineering
Removed the following topics:
•Changing the Conditioner
•Removing the Conditioner
•Installing the Conditioner
Service Dept. and
Engineering
Recommended Lubricants, inside back cover Revised header drive gearbox oil capacity. Engineering
215026 iv Revision A

Serial Number
Record the serial number and model year of the header in the spaces provided below.
1027799
A
Figure 1: Serial Number Location
Header model: R216 Rotary Disc Header
Serial number:
Model year:
The serial number plate (A) is located on the left side of the
header, on top of the end panel.
215026 vRevision A

215026 vii Revision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Serial Number.............................................................................................................................................v
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Safety Alert Symbols ...............................................................................................................................1
1.2 Signal Words .........................................................................................................................................2
1.3 General Safety .......................................................................................................................................3
1.4 Maintenance Safety ................................................................................................................................5
1.5 Hydraulic Safety .....................................................................................................................................6
1.6 Welding Precaution ................................................................................................................................7
1.7 Safety Signs ...........................................................................................................................................8
1.7.1 Installing Safety Decals....................................................................................................................8
1.8 Locating Safety Decals .............................................................................................................................9
1.9 Understanding Safety Signs .................................................................................................................... 11
Chapter 2: Product Overview................................................................................................................... 13
2.1 Specifications....................................................................................................................................... 13
2.2 Component Identification ...................................................................................................................... 15
2.3 Definitions .......................................................................................................................................... 16
Chapter 3: Operation................................................................................................................................ 19
3.1 Break-In Period .................................................................................................................................... 19
3.2 Engaging and Disengaging Header Safety Props ......................................................................................... 20
3.2.1 Engaging and Disengaging Header Safety Props –M1240 Windrower.................................................... 20
3.3 Attaching Rotary Disc Header to M1240 Windrower ................................................................................... 22
3.3.1 Installing Forming Shield ............................................................................................................... 22
3.3.2 Attaching Header to M1240 Windrower........................................................................................... 24
3.3.3 Connecting R216 SP Hydraulics and Electrical to an M1240 Windrower ................................................. 29
3.4 Detaching Header from Windrower ......................................................................................................... 36
3.4.1 Detaching R216 Rotary Disc Header from M1240 Windrower .............................................................. 36
3.4.2 Removing Forming Shield .............................................................................................................. 40
3.5 Driveshields......................................................................................................................................... 42
3.5.1 Opening Driveshields .................................................................................................................... 42
3.5.2 Closing Driveshields...................................................................................................................... 44
3.6 Cutterbar Curtain ................................................................................................................................. 45
3.6.1 Opening Cutterbar Curtain............................................................................................................. 45
3.6.2 Closing Cutterbar Curtain .............................................................................................................. 46
3.7 Header Settings.................................................................................................................................... 47
3.7.1 Cutting Height ............................................................................................................................. 47
Adjusting Skid Shoe Height ........................................................................................................... 48
Adjusting Gauge Roller Height....................................................................................................... 49
3.7.2 Adjusting Cutterbar Angle.............................................................................................................. 52
TABLE OF CONTENTS

215026 viii Revision A
3.7.3 Header Float ............................................................................................................................... 52
3.7.4 Ground Speed ............................................................................................................................. 53
3.8 Conditioner ......................................................................................................................................... 54
3.8.1 Roll Gap ..................................................................................................................................... 54
Adjusting Roll Gap –Steel Rolls ..................................................................................................... 54
Adjusting Roll Gap –Polyurethane Rolls.......................................................................................... 55
3.8.2 Roll Tension ................................................................................................................................ 56
Adjusting Roll Tension ................................................................................................................. 56
3.8.3 Roll Timing.................................................................................................................................. 57
Checking Roll Timing ................................................................................................................... 57
Adjusting Roll Timing................................................................................................................... 57
3.8.4 Forming Shields –Roll Conditioner.................................................................................................. 61
Positioning Forming Shield Side Deflectors –Roll Conditioner............................................................. 61
Positioning Rear Baffle –Roll Conditioner ....................................................................................... 62
3.9 Cutterbar Deflectors ............................................................................................................................. 65
3.9.1 Removing Cutterbar Deflectors....................................................................................................... 65
3.9.2 Installing Cutterbar Deflectors ........................................................................................................ 66
3.10 Haying Tips ........................................................................................................................................ 67
3.10.1 Curing ...................................................................................................................................... 67
3.10.2 Topsoil Moisture ........................................................................................................................ 67
3.10.3 Weather and Topography ............................................................................................................ 67
3.10.4 Windrow Characteristics.............................................................................................................. 68
3.10.5 Driving on Windrow.................................................................................................................... 68
3.10.6 Using Chemical Drying Agents ...................................................................................................... 68
3.11 Transporting the Header ...................................................................................................................... 69
Chapter 4: Maintenance and Servicing.................................................................................................... 71
4.1 Daily Start-Up Check ............................................................................................................................. 71
4.2 Preparing Machine for Servicing.............................................................................................................. 73
4.3 Recommended Safety Procedures ........................................................................................................... 74
4.4 Maintenance Requirements ................................................................................................................... 76
4.4.1 Maintenance Schedule/Record....................................................................................................... 76
4.4.2 Break-In Inspections ..................................................................................................................... 78
4.4.3 Preseason Servicing...................................................................................................................... 78
4.4.4 End-of-Season Servicing ................................................................................................................ 79
4.5 Lubrication .......................................................................................................................................... 80
4.5.1 Greasing Procedure ...................................................................................................................... 80
4.5.2 Lubrication Locations.................................................................................................................... 81
4.6 Cutterbar System.................................................................................................................................. 83
4.6.1 Lubricating Cutterbar.................................................................................................................... 83
Checking and Adding Lubricant in Cutterbar .................................................................................... 83
Draining the Cutterbar................................................................................................................. 86
Filling Cutterbar with Lubricant ..................................................................................................... 87
4.6.2 Cutterbar Discs ............................................................................................................................ 88
Inspecting Cutterbar Discs ............................................................................................................ 89
TABLE OF CONTENTS